Structurally insulated building block

ABSTRACT

A structurally insulated building block that maintains all its qualities across a variety of extreme conditions. The structurally insulated building block includes a first wall, a center portion, and a second wall. The first wall includes a plurality of paired staggered sheets that are overlapped and attached. The second wall includes a first layer, a second layer, and an adhesive. The center portion includes a cork layer the adhesive affixes the paired staggered sheets to without penetrating into center portion, thereby preventing thermal bridging. The first wall, the center portion, and the second wall may also be glued together in a staggered orientation to produce an outer edge that is overlapped and attached with other outer edges of other of the second structurally insulated building blocks.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention is a building block. More specifically, the present invention is a structurally insulated building block.

Description of the Related Art

Structurally insulated panels are commonly utilized to construct various buildings relatively quickly and conveniently. Sometimes referred to as SIPs, these structurally insulated panels are relatively bigger building components that require specialized machinery to install than hollow concrete block or the like.

Structurally insulated building blocks, or SIBBs, are relatively smaller building components that may be assembled into walls, floors, roofs, and other relatively larger building components. SIBBs may also be assembled by hand without the need for specialized machinery or tools to install.

There is a need for a structurally insulated building block that provides humidity regulation and fire safety and maintains all its qualities across a variety of relatively extreme conditions for construction.

BRIEF SUMMARY OF THE INVENTION

The present invention is a building block. More specifically, the present invention is a structurally insulated building block.

It is an object of the present invention to provide a structurally insulated building block that is made from a plurality of relatively lightweight, environmentally friendly, and sustainable materials.

It is an object of the present invention to provide a structurally insulated building block that is relatively easy to assemble into one or more relatively larger building components.

It is an object of the present invention to provide a structurally insulated building block that is relatively light enough for one person to install and require relatively no expertise to install.

It is an object of the present invention to provide a structurally insulated building block that is dry friction fit to create one or more walls, floors, and/or roofs.

It is an object of the present invention to provide a structurally insulated building block that provides an uninterrupted envelope of insulation and sheathing for an entire house or building.

It is an object of the present invention to provide a structurally insulated building block that is utilized in combination with a timber frame and is compatible with other building types and styles.

It is an object of the present invention to provide a structurally insulated building block that includes a lightweight dry fix solution to build walls that require only relatively very basic skills to put together.

It is an object of the present invention to provide a structurally insulated building block that is utilized as an envelope wall around a traditional post and beam timber frame.

It is an object of the present invention to provide a structurally insulated building block that includes a corresponding method for manufacturing the structurally insulated building block.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawings in which like references denote similar elements, and in which:

FIG. 1 illustrates an overhead perspective view of a first structurally insulated building block, in accordance with one embodiment of the present invention.

FIG. 2 illustrates a side cross-sectional perspective view of a second structurally insulated building block, in accordance with one embodiment of the present invention.

FIG. 3 illustrates a side cross-sectional perspective view of a pair of structurally insulated building blocks, in accordance with one embodiment of the present invention.

FIG. 4 illustrates a wall made of a plurality of attached structurally insulated building blocks, in accordance with one embodiment of the present invention.

FIG. 5 illustrates a side perspective view of a plurality of attached first structurally insulated building blocks forming a corner, in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Various aspects of the illustrative embodiments will be described using terms commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. However, it will be apparent to those skilled in the art that the present invention may be practiced with only some of the described aspects. For purposes of explanation, specific numbers, materials, and configurations are set forth in order to provide a thorough understanding of the illustrative embodiments. However, it will be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well-known features are omitted or simplified in order not to obscure the illustrative embodiments.

Various operations will be described as multiple discrete operations, in turn, in a manner that is most helpful in understanding the present invention, however the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations need not be performed in the order of presentation.

The phrase “in one embodiment” is used repeatedly. The phrase generally does not refer to the same embodiment, however, it may. The terms “comprising”, “having” and “including” are synonymous unless the context dictates otherwise.

FIG. 1 illustrates an overhead perspective view of a first structurally insulated building block 100, in accordance with one embodiment of the present invention.

The first structurally insulated building block 100 may include a first wall 110, a center portion 120, and a second wall 130.

The first wall 110 may include a first plurality of paired staggered sheets 112 that are overlapped and attached at a corresponding outer edge 112A of the first paired staggered sheets 112 for increased relative strength. The first wall 110 may be made of Magnesium Oxide board or MGO or the like. The first wall 110 may be approximately at least 12 mm thick or the like. The first paired staggered sheets 112 may be affixed together by a first plurality of adhesive 114 or the like. The first paired staggered sheets 112 may be offset or the like. The first adhesive 114 may be affixed from both an internal side 112C and an external side 112D of the first paired staggered sheets 112 to provide extra relative strength to affixing the first paired staggered sheets 112 together and to have an uninterrupted insulated envelope.

The center portion 120 may include a cork layer 122 or the like. The first adhesive 114 may affix the first paired staggered sheets 112 without penetrating into the center portion 120, thereby preventing thermal bridging.

The second wall 130 may include a second plurality of paired staggered sheets 132 that are overlapped and attached at a corresponding outer edge 132A of the second paired staggered sheets 132 for increased relative strength. The second wall 130 may be made of Magnesium Oxide board or MGO or the like. The second wall 130 may be approximately at least 12 mm thick or the like. The second paired staggered sheets 132 may be affixed together by a second plurality of adhesive 134 or the like. The second paired staggered sheets 132 may be offset or the like. The second adhesive 134 may be affixed from both an internal side 132C and an external side 132D of the second paired staggered sheets 132 to provide extra relative strength to affixing the second paired staggered sheets 132 together and to have an uninterrupted insulated envelope.

The first adhesive 114 and the second adhesive 134 may be made from Lakeland Paints as Lakeland Wood Glue in Lakeland Paints, Unit 19, Heysham Business Park, Middleton Road, Heysham, LA3 3PP 01524 852371 or the like.

The first adhesive 114 and the second adhesive 134 may be applied only in a factory or the like where the first structurally insulated building blocks 100 are glued together and are not applied onsite.

FIG. 2 illustrates a side cross-sectional perspective view of a second structurally insulated building block 200, in accordance with one embodiment of the present invention.

The second structurally insulated building block 200 may include a first wall 210, a center portion 220, and a second wall 230.

The first wall 210 may include a first plurality of paired staggered sheets 212 that are overlapped and attached at a corresponding outer edge 212A of the first paired staggered sheets 212 for increased relative strength. The first wall 210 may be made of Magnesium Oxide board or MGO or the like. The first wall 210 may be approximately at least 12 mm thick or the like. The first paired staggered sheets 212 may be affixed together by a first plurality of adhesive 214 or the like. The first paired staggered sheets 212 may be offset or the like.

The center portion 220 may include 3 cork layers 220A or the like. The 3 cork layers 220A may be attached in horizontal sequence side-by-side-by-side between the first wall 210 and the second wall 230 with a second plurality of adhesive 215 or the like to increase insulation and the like. The second adhesive 215 may be made from Lakeland Paints as Lakeland Wood Glue in Lakeland Paints, Unit 19, Heysham Business Park, Middleton Road, Heysham, LA3 3PP 01524 852371 or the like.

The second wall 230 may include a second plurality of paired staggered sheets 232 that are overlapped and attached at a corresponding outer edge 232A of the second paired staggered sheets 232 for increased relative strength. The second wall 230 may be made of Magnesium Oxide board or MGO or the like. The second wall 230 may be approximately at least 12 mm thick or the like. The second paired staggered sheets 232 may be affixed together by a third plurality of adhesive 234 or the like. The paired staggered sheets 232 may be offset or the like.

FIG. 3 illustrates a side cross-sectional perspective view of a pair of structurally insulated building blocks 300, in accordance with one embodiment of the present invention. More specifically, FIG. 3 illustrates the third structurally insulated building block 300 being attached together making a wall (not shown).

The third structurally insulated building block 300, may include a first wall 310, a center portion 320, and a second wall 330.

The first wall 310 may include a first plurality of paired staggered sheets 312 that are overlapped and attached at a corresponding outer edge 312A of the first paired staggered sheets 312 for increased relative strength. The first wall 310 may be made of Magnesium Oxide board or MGO or the like. The first wall 310 may be approximately at least 12 mm thick or the like. The first paired staggered sheets 312 may be affixed together by a first plurality of adhesive 314 or the like. The first paired staggered sheets 312 may be offset or the like.

The center portion 320 may include a pair of cork layers 320A or the like. The pair of cork layers 320A may be attached in vertical sequence one on top of the other between the first wall 310 and the second wall 330 with a first plurality of screws 315 or the like for a broader insulation. The first screws 315 may be a first plurality of drywall screws 315A or a first plurality of wooden screws 315B or the like. The pair of cork layers 320A may be offset from the first wall 310 and the second wall 330.

The second wall 330 may include a second plurality of paired staggered sheets 332 that are overlapped and attached at a corresponding outer edge 332A of the second paired staggered sheets 332 for increased relative strength. The second wall 330 may be made of Magnesium Oxide board or MGO or the like. The second wall 330 may be approximately at least 12 mm thick or the like. The second paired staggered sheets 332 may be affixed together with a second plurality of screws 335 or the like. The second screws 335 may be a second plurality of drywall screws 335A or a second plurality of wooden screws 335B or the like. The second paired staggered sheets 332 may be offset or the like. The first screws 315 and the second screws 335 affix an outer rim (not shown) of each of the first paired staggered sheets 312 and the second paired staggered sheets 335 together.

FIG. 4 illustrates a wall 400 made of a plurality of attached structurally insulated building blocks 410, in accordance with one embodiment of the present invention.

The wall 400 may include a plurality of structurally insulated building blocks 410, a plurality of screws 420, a first side 430, and a second side 440.

The structurally insulated building blocks 410 may include a first structurally insulated building block (FIG. 1, 100 ), a second structurally insulated building block (FIG. 2, 200 ), a third structurally insulated building block (FIG. 3, 300 ), or the like. The screws 420 may include a plurality of drywall screws 420A or a plurality of wooden screws 420B or the like. The first side 430 may receive the screws 420 along its entire length. The first side 430 may be a side surface 432 of one of the structurally insulated building blocks 410. The second side 440 may receive the screws 420 that continuously extend from the first side 430 along the second side 440 of one of the structurally insulated building blocks 410. The second side 440 may receive the screws 420 along its entire length. The second side 440 may be a bottom side surface 442 of one of the structurally insulated building blocks 410.

FIG. 5 illustrates a side perspective view of a plurality of attached first structurally insulated building blocks 100 forming a corner 150, in accordance with one embodiment of the present invention.

The attached first structurally insulated building blocks 100 may include a first wall 110, a center portion 120, and a second wall 130.

The first wall 110 may include a plurality of first paired staggered sheets 112 that are overlapped and attached together. The first paired staggered sheets 112 may each include a corresponding outer edge 112A for increased relative strength. The first paired staggered sheets 112 may be affixed together by a first adhesive (FIG. 1, 114 ) or the like. The first paired staggered sheets 112 may be offset or the like. The first adhesive 114 may be affixed from both an internal side 112C and an external side 112D of the first paired staggered sheets 112 to provide extra relative strength to affixing the first paired staggered sheets 112 together and to have an uninterrupted insulated envelope.

The center portion 120 may include a cork layer 122 having a plurality of sections 122B that are both vertically and horizontally attached and oriented in sequence between the first wall 110 and the second wall 130 with a second adhesive 124 or the like for a broader insulation. The first adhesive 114 may affix the first paired staggered sheets 112 without penetrating into the center portion 120.

The second wall 130 may include a second plurality of paired staggered sheets 132 that are overlapped and attached at a corresponding outer edge 132A of the second paired staggered sheets 132 for increased relative strength. The second wall 130 may be made of Magnesium Oxide board or MGO or the like. The second wall 130 may be approximately at least 12 mm thick or the like. The second paired staggered sheets 132 may be affixed together with a third plurality of adhesive 135 or the like. The third adhesive 135 may be made from Lakeland Paints as Lakeland Wood Glue in Lakeland Paints, Unit 19, Heysham Business Park, Middleton Road, Heysham, LA3 3PP 01524 852371 or the like.

A method for manufacturing a structurally insulated building block is relatively complex.

The overall method may include the steps of obtaining a first wall, a center portion, and a second wall and attaching the first wall and the second wall on opposite sides of the center portion.

The obtaining step may include the first wall and the second wall each includes a pair of paired staggered sheets that are overlapped and attached at an outer edge of the paired staggered sheets for increased strength and a middle portion. The obtaining step may include each of the pair of paired staggered sheets are attached by a first plurality of adhesive and a second plurality of adhesive. The obtaining step may include the first wall and the second wall are made of Magnesium Oxide board.

The attaching step may include the first adhesive affixing the paired staggered sheets without penetrating the center portion, thereby preventing thermal bridging. The attaching step may include the center portion is made of cork.

While the present invention has been related in terms of the foregoing embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described. The present invention can be practiced with modification and alteration within the spirit and scope of the appended claims. Thus, the description is to be regarded as illustrative instead of restrictive on the present invention. 

What is claimed is:
 1. A structurally insulated building block, comprising: a first wall having a first plurality of paired staggered sheets; a center portion having a first side, and a second side; and a second wall having a second plurality of paired staggered sheets; wherein the first wall is attached to the first side of the center portion and the second wall is attached to the second side of the center portion.
 2. The structurally insulated building block, according to claim 1, wherein the first paired staggered sheets are overlapped and attached at an outer edge of the first paired staggered sheets for increased strength.
 3. The structurally insulated building block, according to claim 1, wherein the first paired staggered sheets are affixed together by a first plurality of adhesive from both an internal side and an external side of the first paired staggered sheets to produce an uninterrupted insulated envelope.
 4. The structurally insulated building block, according to claim 1, wherein the center portion is made of cork.
 5. The structurally insulated building block, according to claim 4, wherein the center portion is made of 3 cork layers.
 6. The structurally insulated building block, according to claim 5, wherein the 3 cork layers are attached in horizontal sequence side-by-side-by-side between the first wall and the second wall with a third plurality of adhesive.
 7. The structurally insulated building block, according to claim 4, wherein the center portion is made of a pair of cork layers.
 8. The structurally insulated building block, according to claim 7, wherein the pair of cork layers are attached in vertical sequence one on top of the other between the first wall and the second wall with a first plurality of screws for a broader insulation.
 9. The structurally insulated building block, according to claim 8, wherein the first screws are a first plurality of drywall screws.
 10. The structurally insulated building block, according to claim 8, wherein the first screws are a first plurality of wooden screws.
 11. The structurally insulated building block, according to claim 7, wherein the pair of cork layers is offset from the first wall and the second wall.
 12. The structurally insulated building block, according to claim 1, wherein the second paired staggered sheets are overlapped and attached at an outer edge of the second paired staggered sheets for increased strength.
 13. The structurally insulated building block, according to claim 12, wherein the second paired staggered sheets are affixed together by a second plurality of screws.
 14. The structurally insulated building block, according to claim 13, wherein the second screws are a second plurality of drywall screws.
 15. The structurally insulated building block, according to claim 14, wherein the second screws are a second plurality of wooden screws.
 16. The structurally insulated building block, according to claim 1, wherein the first wall and the second wall is made of Magnesium Oxide board.
 17. The structurally insulated building block, according to claim 1, wherein the adhesives are made of organic materials and withstand external elements and are free of volatile compounds and do not contribute to pollution or global warming.
 18. The structurally insulated building block, according to claim 1, wherein the adhesives affix without penetrating into the center portion, thereby preventing thermal bridging.
 19. The structurally insulated building block, according to claim 1, wherein the first paired staggered sheets and the second paired staggered sheets are offset.
 20. The structurally insulated building block, according to claim 1, wherein the first wall, the center portion, and the second wall are glued together in a staggered orientation to produce an outer edge that is overlapped and attached with other outer edges of another of the second structurally insulated building blocks for increased strength to construct a wall, a floor, or a roof. 